HVAC support and mounting system

ABSTRACT

A system for mounting and supporting an HVAC system on a curb in which a collar is provided and fitted on the curb, and the collar provides risers which connect to the supply and return lines of the system. The HVAC unit is fitted on the collar and engages the supply and return risers in air tight relation. The system further accumulates moisture and water on, or in proximity to, the system and directs it to a remote location.

The present invention relates, in a general sense, to heating, ventilation and air conditioning systems and, more particularly, to the installation and support of HVAC systems installed and mounted on roofs and pads at less than roof height.

BACKGROUND OF THE INVENTION

1. Field of the Invention

Heating, ventilation and air conditioning equipment, affectionately lumped together under the acronym HVAC, has become standard in new construction and remodeling, to add or upgrade HVAC equipment, and has become big business.

Energy costs appear to be a prime mover in the determination of whether and, if so, what type and brand of unit is best suited to one's home or business. There are a large number of options available, most of which trumpet their efficiency and power, concepts which are typically, but not mutually, exclusive.

Hand in hand with the laudable goal of saving energy is reduction of leakage, which reduces the amount of treated air which, by virtue of gaps in the installation, leaks into untreated spaces.

In most residential and some commercial installations, the operating equipment sits on a curb. The curb is a sheet metal construction and is typically supported on a slab on a ground installation and on a roof installation, and, in particular, where the roof is pitched, the curb is specially constructed to fit the pitch so as to support the operating equipment in a vertical plane.

Experience has demonstrated that the position of the equipment, not much more efficient as it is seated on the curbing, is a large source of leakage, with a consequent loss of efficiency and compromising the savings attributable to more efficient heating and cooling equipment. The present invention addresses this problem and offers a solution.

2. Overview of the Prior Art

Over the last several years, as there has been an enhanced interest in conservation of energy, there has been a commensurate interest in minimizing, if not eliminating, leaks in HVAC systems.

By way of example, Gillispie, in his U.S. Pat. No. 5,687,514, suggests that the leveling of a curb is a difficult problem, and that one way to address the problem is to place an upper portion within a lower portion with the upper portion being slightly smaller than the lower so that the orientation of the upper portion can be adjusted to level the equipment mounted to it. It is a clever solution to the leveling problem, but no solution to the leakage problem.

A similar concept governs the structure disclosed in Rutledge U.S. Pat. No. 6,343,439, wherein a slidable pin holds the support curb relative to the base curb.

A couple of other patents are noted in passing, although they relate to the manner of joining various panels of a curb and in no way relate to the present invention. Thus, we visit Rummo, Jr. et al. U.S. Pat. No. 5,465,533, and Brown et al. U.S. Pat. No. 6,041,557, both of which are systems for connecting the various panels that form a curb. Brown, in particular, reflects the current thinking with respect to curbing. Note the cross members 28, 30 and 32 which are intended to divide the curbing into distinct passages for supply and return air and also result in potentially heavy leakage.

SUMMARY OF THE INVENTION

The present invention has as its focus the provision of a novel mounting and support system for a variety of HVAC units which are typically mounted out of doors, on pads and roofs, including pitched roofs.

One of the objectives to be accomplished by the present invention is the substantial elimination of leakage of conditioned air at the point of proper mounting of the HVAC unit to the duct system. It is an objective related to the foregoing to eliminate the migration of conditioned air between the supply and return air sides.

It is another objective of the present invention to provide a collar which provides a uniform, and substantially air tight, transition between a typical curbing and the HVAC unit itself.

A further objective is to provide drainage which guides both condensate and rain away from the entire assembly and off any roof installation in an effort to minimize the growth of algae and mold organisms in and around the unit itself, as well as around shingles, tiles and the like.

Yet another, and further, objective of the present invention is to provide a collar for the mounting of an HVAC unit on a curb which is aesthetically pleasing and installation having all of the benefits attributed to it.

The foregoing, as well as other objectives and benefits, will become evident to those skilled in the art when the following Detailed Description of a Preferred embodiment is read in conjunction with the drawings, wherein:

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a pictorial representation of an installation of a roof mounted HVAC unit embodying a collar of the present invention;

FIG. 2 is an exploded view of a curb and collar demonstrating the structure and inter-relationship between these two elements;

FIG. 3 illustrates the gasket which adheres to a flange along the periphery of the supply and return ducting;

FIG. 4 illustrates ducting with a lip at the end of the flange and a gasket which is particularly adapted for use with such a flange;

FIG. 5 is a side elevation illustrating, in profile, a gasket for use on a straight flange such as that of FIG. 3;

FIG. 6 is a side elevation of the profile of a gasket suitable for use on a flange with a lip thereon;

FIG. 7 is an exploded pictorial view, in perspective, showing the interrelationship between the HVAC unit and the collar of the present invention;

FIG. 8 is a view similar to that of FIG. 1, partially cut away to illustrate, in particular, the drain pan of the collar of the present invention and the path of moisture generated during operation of the HVAC unit; and,

FIG. 9 is a cut away of a side elevation of the collar of the present invention as it sits on a curb, illustrating the drainage system.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENT

With reference now to the drawings, and initially to FIG. 1, a pictorial representation of a typical HVAC system installation 20 on a pitched roof, is illustrated.

The installation includes a conventional curb 22 secured to the roof of a structure, in any suitable fashion, an HVAC unit 24, and a novel collar unit 26, constructed in accordance with the present invention and adapted to receive the HVAC unit. The HVAC, which may be any one of available units, receives air to be conditioned from a return line and conditioned air through a supply line.

Moving to FIG. 2, the curb structure, which is relatively standard, is shown in some detail. The curb 22 is typically of a rectangular structure, having upstanding walls 31, circumscribed by a flange 33. Where the roof R is pitched, the lower surface, or edge, 35 of the parallel walls 31 is canted to match the pitch of the roof. The upper edges 37 of all of the walls 31 vary in height so as to support the collar 26 in a horizontal attitude.

Still referring to FIG. 2 and, secondarily, to FIG. 7, the collar 26, in keeping with the invention, provides a unique platform for the HVAC unit 24 which minimizes leakage and creates an exceptionally easy custom fit for all such units.

In accomplishing the objectives of the invention, the collar 26 becomes an efficient mechanical coupling between the curb 22 and the HVAC unit 24. In order to accommodate a variety of different HVAC units available on the market, the collar of the present invention, which may be formed from sheet metal or any other suitable material, including certain plastics, is shown as having a stepped, or tiered, structure allowing the bottom and top openings to be different sizes which permits any HVAC unit to be accommodated on the curb.. Referring to FIGS. 3, 7 and 9, the collar 26 includes a lower section 45, an intermediate section 47, and an upper section 49. The lower section 45 is fabricated to engage the curb 22, and the upper section 49 is fashioned to receive the specific HVAC unit to be used. The intermediate section 47 provides a smooth transition between the upper and lower section where a difference in size makes a transition appropriate. It will also be appreciated that the frame of the collar may be readily fabricated from a single piece of material and in a single process without departure from the invention.

Returning to the collar 26, an important feature of the curb is its drainage system, which has the ability to collect and disperse both moisture which accumulates during operation of the HVAC units evaporator, as well as from outside environmental sources. In order to disperse and dispose of accumulated moisture, the bottom of the collar is formed with a drain pan 52. The drain pan 52 has sloping walls leading to a low point, and the HVAC unit's drain line is directed into the drain pan.

Referring to FIG. 9, at the center of the concavity of the drain pan 52 is a drain hole 54, which is fitted with a discharge line 56. The discharge line may be positioned to carry away, and off the roof, any accumulated moisture from any source. In so doing, minerals and algae forming materials are not allowed to accumulate on shingles or other roofing materials.

The novel collar construction has the further advantage of being able to capture and remove environmentally derived moisture, in the form of rain or fog, which may develop from time to time. This is accomplished by making the outer upstanding perimeter wall 58 of the upper section 49 slightly larger, perhaps by 1″, than the perimeter of the HVAC unit. In this manner, rain falling on or about the unit enters the collar through the space between the unit and the curb wall, where it moves to the drain hole 54, and it is carried away from the installation 20. Arrows on FIGS. 8 and 9 indicate the flow of environmentally generated moisture, resulting in no accumulation, with a consequent savings in maintenance.

It is another important feature-of the invention that leakage of conditioned air, whether heated or cooled, is kept to an absolute minimum. To this end, risers 61 and 63 are affixed over companion openings in the drain pan immediately above the supply and return ducts from the structure to be air conditioned. Duct extensions, sometimes referred to as cans, are constructed to be snugly fitted into the risers and extend below the collar where they may be connected to the ducting from the structure to be air conditioned.

Leakage is a persistent problem in conventional installations at the HVAC as it is mounted on the curb 22, or with the present invention, on the collar. An objective of the present invention is to obviate that leakage, and, to that end, gaskets 65 and 67 are provided about the perimeter of the risers 61 and 63 where they are aligned in mating engagement with the appropriate outlet, which is a horizontal plate 68 in the HVAC unit. The edge of the plate and the flange are seated against one another when the HVAC unit is lowered into place.

Referring to FIGS. 3 and 4, the risers and the duct extensions are finished with inwardly facing transverse flanges, such as at 69 and 70. The flanges overlap on the duct extensions and the risers, with the gaskets circumscribing the flanges, thereby perfecting the seal. There are different gaskets for different flange configurations. Two such gaskets are shown, the only significant difference being that flange 70 terminates in an upstanding lip 70. The invention contemplates different gaskets to accommodate these differences. Gasket 65, illustrated in FIG. 5, is formed with a slot 73 having a series of teeth 75, which, when slipped over the flange 69, grip the surface thereof and hold the gasket in place. In the case of FIG. 6, a slot 78 in gasket 67 terminates in a transverse slot 80, so that when the gasket is slipped onto the flange 70, the transverse slot 80 encompasses the lip 71, holding the gasket in place.

It will be understood that the gasket is designed to accommodate the flange upon which it is to reside, and that it was not intended to indicate that one or the other of the risers had a specific form of the flange.

Once the appropriate gasket is in place, the HVAC unit is lowered into place on the collar, compressing the gasket and effecting an air tight seal.

Having now described a preferred embodiment of the present invention, it will be appreciated that some variations in structure and operation may occur to those skilled in the art, and such variations are within the contemplation of the invention and the scope of the claims, wherein: 

1. An HVAC mounting and support system for installation of an HVAC unit on a curb, wherein said system includes a supply line for providing air to be conditioned to said system, and a return line for directing conditioned air to an area to be conditioned; the system comprising, in addition to the curb; a collar, said collar being mounted on said curb, said collar having upstanding risers thereon, said risers being aligned and engaged with the supply and return lines in said curb; said collar adapted to receive and support said HVAC unit.
 2. The HVAC mounting and support system of claim 1 having a drainage system in said collar, said drainage system adapted to receive condensation from the HVAC unit and direct such condensation to a location remote from said system.
 3. The HVAC mounting and support system of claim 1, wherein said drainage system is configured to capture environmentally generated moisture and guide such moisture away from said HVAC unit.
 4. The HVAC mounting and support system of claim 1, wherein said HVAC unit being provided with a bottom plate, openings in said bottom plate being provided for supply and return air; said openings in said HVAC unit and said risers in said collar being aligned and sealed with one another when said HVAC unit is in place.
 5. The HVAC mounting and support system of claim 1, said collar having a lower section, an intermediate section and an upper section; said lower section being sized so as to encompass said curb; and said upper section being sized to receive said HVAC unit.
 6. The HVAC mounting and support system of claim 5, wherein a space is provided between the perimeter of said HVAC system and the perimeter of said collar, said space adapted to receive environmentally created moisture.
 7. The HVAC mounting and support system of claim 3, wherein said drainage system includes a drainage pan, said drainage pan having an opening at the base thereof, a tube connected to said drainage pan about said hole wherein condensation accumulated in said drainage pan is directed away from said mounting and support system.
 8. The HVAC mounting and support system of claim 4, wherein a gasket is provided to seal said risers in said collar with said HVAC unit.
 9. The HVAC mounting and support system of claim 8, wherein said risers terminate in flanges, said flanges facing inward and parallel to said bottom plate, and said gasket circumscribes the edges of said risers and said bottom plate.
 10. The HVAC mounting and support system of claim 2, wherein said drainage system is configured to capture environmentally generated moisture and guide such moisture away from said HVAC unit. 